Multi-configuration vehicle door system

ABSTRACT

A modular door system provides a lower door assembly, an upper door assembly and a trim assembly. The upper door assembly is selectively removable and replaceable such that the door system is readily converted between a multiple of configurations. The trim assembly includes the interior vehicle door trim and a hinged trim portion. The hinged trim portion is defined by a trim hinge which is generally parallel to the open edge. By pivoting the hinged trim portion away from the open edge, the cavity is readily exposed for receipt of the upper door assembly. The difference in thickness of the upper door assembly is accommodated by pivoting of the hinged trim portion to permit passage of the components while still providing a seal for the cavity when the hinged trim portion is secured.

The present application claims priority to U.S. Provisional PatentApplication Ser. No. 60/525084, filed Nov. 25, 2003.

BACKGROUND OF THE INVENTION

Some vehicles include multiple door configurations that may be utilizedin various environments. Such configurations typically include a rigidfull door with a movable window, a door with a soft upper portion thatoften includes a zip out portion, a half-door, and complete doorremoval.

Numerous conventional vehicle door designs provide assembly arrangementssuch that the door may be converted from one configuration to another. Alower door housing portion of the door structure typically carries awindow regulating mechanism which displaces a window panel. The lowerdoor housing portion also includes door closure systems such as latchesto secure the door to the vehicle body. Such mechanisms complicatereconfiguration of the door.

One modular door generally includes a lower door housing defining acavity adapted to receive a glass panel and an upper cassette includinga housing carrying a track for displaceably mounting the glass panelwith respect to the upper housing and a regulator for controllingdisplacement of the glass panel along the track. The cassette isremovably attached as a unit to the lower door housing to selectivelyexpose the passenger compartment through a large portion of the dooropening in the vehicle body and to permit substitution of a soft upperdoor portion.

One disadvantage with such a modular door is sealing the cavity whenvarious upper door portions are attached thereto. Typically, additionalseal components and the like are attached to the cavity opening to sealthe selected upper door housing to the lower door housing. Suchadditional seal components may complicate changeover for an end user.

Accordingly, it is desirable to provide an uncomplicated modular doorsystem that is readily converted between configurations.

SUMMARY OF THE INVENTION

The modular door system according to the present invention provides alower door assembly, an upper door assembly and a trim assembly. Theupper door assembly is selectively removable and replaceable such thatthe door system is readily converted between a multiple ofconfigurations

The upper door portion is selected from one of a door cassette and aside curtain assembly. The lower door assembly generally includes aninner panel and an outer panel mounted to a frame that defines a cavityto receive one of the upper door portions through an open edge.

The trim assembly includes interior vehicle door trim and a hinged trimportion. The hinged trim portion is defined by a trim hinge which isgenerally parallel to the open edge. By pivoting the hinged trim portionaway from the open edge, the cavity is readily exposed for attachment ofthe upper door assembly. The difference in thickness of the upper doorassembly is accommodated by pivoting of the trim portion to permitpassage of various thickness components while still providing a seal ofthe cavity when the hinged trim portion is secured.

The present invention therefore provides an uncomplicated modular doorsystem that is readily converted between configurations.

BRIEF DESCRIPTION OF THE DRAWINGS

The various features and advantages of this invention will becomeapparent to those skilled in the art from the following detaileddescription of the currently preferred embodiment. The drawings thataccompany the detailed description can be briefly described as follows:

FIG. 1 is a side view of an exemplary vehicle incorporating a doorsystem constructed in accordance with the present invention;

FIG. 2 is an exploded perspective view of a modular door assembly of thepresent invention;

FIG. 3 is a perspective end view of the modular door assembly showingone possible arrangement to accommodate latch and related rods or cableswithin the door assembly;

FIG. 4 is a sectional view of the rear attachment of the door cassetteto the door frame;

FIG. 5 is a sectional view of the front attachment of the door cassetteto the door frame;

FIG. 6 is a mid sectional view of a modular door system with a moveableglass;

FIG. 7 is an end sectional view of a modular door system with a softupper door assembly.

FIG. 8 is a mid sectional view of a modular door system with a softupper door assembly of FIG. 7.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 1 illustrates a general perspective view of a door system 10 for avehicle 12. It should be understood that various vehicles would benefitfrom the present invention. The vehicle door system 10 generallyincludes a lower door assembly 14 and an upper door assembly 16. Theupper door assembly 16 is preferably selectively removable andreplaceable such that the door system 10 is readily converted between amultiple of configurations. It should be understood that relativepositional terms such as “forward,” “aft,” “upper,” “lower,” “above,”“below,” and the like are with reference to the normal operationalattitude of the vehicle and should not be considered otherwise limiting.

The lower door assembly 14 includes a hinge arrangement 15 or the likewhich permits the door system 10 to pivotally attached to the vehicle 12in a conventional manner.

Referring to FIG. 2, the door system 10 generally includes the lowerdoor assembly 14 which includes a door frame 18 and a trim assembly 20.The upper door assembly 16 is selected from at least one of a doorcassette 22 and a side curtain assembly 24. It should be understood thatother upper door portions 16 along with no upper door assembly 16 willalso benefit from the present invention.

The door cassette 22 includes a movable glass window 26 and drivearrangement 28. The door cassette 22 is primarily of a rigidconstruction. The door cassette 22 includes attachments 21 to secure thedoor cassette 22 to the lower door assembly 14.

The curtain assembly 24 includes a soft canvas and clear plastic window28 mounted over a frame 30. The curtain assembly 24 is primarily of asoft construction. The frame 30 defines attachments 31 to secure thecurtain assembly 24 to the lower door assembly 14.

The lower door assembly 14 generally includes an inner panel 32 and anouter panel 34 mounted to the frame 18. The frame 18 defines a cavity 36which receives one of the upper door assembly 16 along an open edge 38.A front face 40 and a rear face 42 of the frame 18 includes fastenerapertures 44 a-d, to receive a fastener 46 such as a bolt (FIG. 3).Preferably, the bolt heads are exposed along the faces 40, 42 for accessand aesthetic reasons.

The trim assembly 20 includes the interior vehicle door trim(illustrated schematically at 48) and a hinged trim portion 50, plushardware elements needed for various functions of the door, such aslatch and related rods or cables, inside door handle, etc. The trimassembly 20 is secured to the door frame 18 with a hook 53 andattachment 55 arrangement which permits the trim to be readily removedand secured to the door frame 18 by an end user.

The hinged trim portion 50 is defined by a trim hinge 52 which isgenerally parallel to the open edge 38. The trim hinge 52 is preferablya living hinge which permits the trim portion to pivot about the hinge52 (illustrated by arrow H). By pivoting the hinged trim portion 50 awayfrom the open edge 38, the cavity 36 is readily exposed for passage ofthe door cassette 22 and any associated components such as the windowdrive arrangement 28.

The glass window 26 and the soft canvas and clear plastic windowassembly 28 are of generally the same thickness but the drivearrangement 28 required to guide and move the glass window 26 issignificant thicker. This difference in thickness is accommodated bypivoting of the trim portion 50 to permit passage of the thickercomponents.

Referring to FIG. 4, the fastener 46 a secures the attachment 21 a to anupper portion of the frame 18 adjacent the door inner panel 32 to securethe curtain assembly 24 to the lower door assembly 14. Preferably,fastener apertures 44 a and 44 b are slots to receive fasteners 46 a and46 b respectively.

Referring to FIG. 5, fasteners 46 c and 46 d secure the attachments 21 cand 21 d to the front portion of the door frame 18 when the cassette 22is located within the cavity 36. Preferably, the fastener aperture 46 cis located within a recess 52 in the front face of the door frame 18 toprovide clearance for the fasteners 46 c and 46 d.

Referring to FIG. 6, once the door cassette 22 is secured into thecavity 36, the trim assembly 20 is located upon the door frame 18 withthe hook 53. The attachment 55 is then secured to the door frame 18(FIG. 1) with fasteners 57 or the like to secure the trim assembly 20thereto. It should be understood that various attachments will benefitfrom the present invention.

Once the trim assembly 20 is secured, the hinged trim portion 50 ispivoted along the trim hinge 52 to close the open edge 38. The hingedtrim portion 50 includes a reinforcement structure 54. It should beunderstood that various materials and constructions will benefit thereinforcement structure. The reinforcement structure defines a trimportion attachment 56 which is secured to the frame 18 with a trimfastener 58 or the like. Again, the fasteners are preferably readilyaccessible from the outside of the frame so as to permit access for anend user.

A seal 60 extends from the reinforcement structure 54. The seal 60, oncethe trim portion is secured, rides against the window glass 26 toprovide a seal for the cavity 36. A fixed seal 62 extends from the doorouter panel 34. The window glass 26 is movable therebetween.

Referring to FIG. 7, the frame 30 of the curtain assembly is installedwithin mounts 64 located within the frame 18 and the trim assembly 20 issecured as described above. Preferably, the mounts 64 are located on theinside of the front face 40 and rear face 42 of the frame 18. A biasingassembly 66 such as a spring or the like provides a resilient interfacebetween the frame 30 and the mounts 64 to minimize vibration and noise.The curtain assembly 24 is thereby retained between the seals 60, 62(FIG. 8) as described above.

Even without an upper door portion, the seals 60, 62 will effectivelytouch each other thereby sealing the cavity 36. No separate seal memberis required.

The foregoing description is exemplary rather than defined by thelimitations within. Many modifications and variations of the presentinvention are possible in light of the above teachings. The preferredembodiments of this invention have been disclosed, however, one ofordinary skill in the art would recognize that certain modificationswould come within the scope of this invention. It is, therefore, to beunderstood that within the scope of the appended claims, the inventionmay be practiced otherwise than as specifically described. For thatreason the following claims should be studied to determine the truescope and content of this invention.

1. A vehicle door system comprising: a lower door assembly defining acavity, said cavity open adjacent an edge of said lower door assembly;an upper door assembly at least partially receivable within said cavity;and a trim assembly mountable to said lower door assembly, said trimassembly comprising a hinged trim portion movable to engage said upperdoor assembly and at least partially seal said cavity.
 2. The vehicledoor system as recited in claim 1, wherein said hinged trim portioncomprises a living hinge.
 3. The vehicle door system as recited in claim1, wherein said hinged trim portion is defined substantially parallel tosaid edge.
 4. The vehicle door system as recited in claim 1, whereinsaid upper door assembly comprises a door cassette.
 5. The vehicle doorsystem as recited in claim 4, wherein said door cassette comprises amovable glass window.
 6. The vehicle door system as recited in claim 1,wherein said upper door assembly comprises a side curtain assembly. 7.The vehicle door system as recited in claim 1, wherein said hinged trimportion comprises a reinforcement structure.
 8. The vehicle door systemas recited in claim 7, further comprising a seal extending from saidreinforcement structure.
 9. The vehicle door system as recited in claim1, wherein said lower door assembly comprises a frame.
 10. The vehicledoor system as recited in claim 9, wherein said trim assembly comprisesa hook engageable with said frame.
 11. The vehicle door system asrecited in claim 10, wherein said hook is adjacent said hinged trimportion.
 12. The vehicle door system as recited in claim 9, wherein saidtrim assembly comprises an attachment engageable with said frame.
 13. Amethod of configuring a vehicle door comprising the steps of: (1)removably mounting an upper door assembly within a cavity defined by alower door assembly; and (2) pivoting a hinged trim portion to engagethe upper door assembly and at least partially close the cavity.
 14. Amethod as recited in claim 13, further comprising the step of: attachinga trim assembly to the lower door assembly prior to said step (2).
 15. Amethod as recited in claim 13, wherein said step (1) further comprises:resiliently mounting the upper door assembly to the lower door assembly.16. A method as recited in claim 13, further comprising the steps of:removing fasteners from the trim portion; and pivoting the trim portionaway from the cavity prior to said step (1).
 17. A method as recited inclaim 13, further comprising the step of: securing the hinged trimportion to the lower door assembly after said step (2).